PWS,_Inline_Chiller_and_auto_hydraulic_hose_reels_27_Mar_2017_Draft.docx

Performance Work Statement (PWS)

MOUNTED INLINE CHILLER AND AUTO HYDRAULIC HOSE REELS

309th AIRCRAFT MAINTENANCE GROUP

OGDEN AIR LOGISTICS COMPLEX (OOALC)

HILL AIR FORCE BASE, UTAH 84056

Project Engineer: Kirt Ehlers Civ 309 AMXG/ENL

March 14, 2017

Table of Contents

Scope

Hill Air Force Base (HAFB) has twenty five F-35 Control Consoles (CCs) that are located in Buildings 225 (Appendix D) and 233 (Appendix E). The CCs have controlled air-conditioning and hydraulic plumbing that pass through them. The CC air-conditioning outlet is connected to a Portable Inline Chiller Unit (PICU) that is used to reduce the air conditioned temperature of 75-55°F even lower at the aircraft point of use.

The hydraulic hoses used for testing are stored on a metal frame stand and wound and un-wound by hand when needed.

A requirement is needed to reconfigure the PICU to a permanently Mounted Inline Chillers (MIC) and build new MICs from scratch near each CC. In the same area as the MIC, the hydraulic hoses need to be converted to Auto Wind Hose Reels (AWHR)

Design Requirements

All CCs shall have a permanently Mounted Inline Chiller (MIC) and Auto Wind-up Hydraulic Hose Reel (AWHR) as near as possible.

Note: Mounted Inline Chiller (MIC) is equivalent to the following:

· Converting components from 9-10 PICUs to a MIC.

· Building 15-16 new MICs.

Requirement #1: Build New Mounted Inline Chiller (MIC)

The contactor shall design, build, assemble/install 15 or 16 MICs that reduce CCs conditioned air (75-50°F) down to 51-34°F at pint of use on the aircraft.

Contractor to design, build, assemble/install 15 or 16 MICs with new components from scratch that would match the performance and capacity of the original 9 or 10 PICUs that are converted to MIC units.

The new MIC design shall incorporate the basic specifications of Section 2.2 but with all new components and have the same comparable outputs.

The MIC design shall incorporate Section 2.3, Requirement #3, and using minimal floor space.

Additional requirements see Section 2.4, and 2.5.

Requirement #2: Portable Inline Chillers (PICU) converted to a Mounted Inline Chillers (MIC)

The contractor shall collect sample base line data of current PICUs for validating that the MICs will function the same or better. Data collected to include but not limited to, air flow, humidity, pressure, temperature. The data/ process must be approved by the Government before the conversion takes place.

The contactor shall design, build, and assemble/convert PICUSs to MICs that reduce CCs conditioned air (75-50 ° F) down to 51-34°F at pint of use on the aircraft.

Contractor shall convert a minimum of 9 and maximum of 10 PICUs located at HAFB into MICs using the existing major components from the PICUs (such as controls, probe connection, compressor, and heat exchanger), reassemble them mounted permanently near each CC, plumbed with insulated ductwork and required temperature control connections.

The MIC shall have the same operator interface or equivalent features as the PICU such as switches, gages, alarm, and indicator lights.

The PICU conversion to a MIC design shall incorporate Requirement #3, Section 2.3 and using minimal floor space.

Additional requirements see Section 2.4, and 2.5.

Requirement #3: Auto Wind-up Hydraulic Reel (AWHR)

The CC has a max hydraulic operating pressure of 4500 psi. Connected to each CC are five 70-foot long hydraulic hoses, four with a 1.7-inch outer diameter (OD) and one hose with a 0.5-inch outer diameter. These hydraulic hoses are manually unwrapped off a hose rack when in use and manually wrapped onto the rack for storage when not in use.

The contractor shall design and build up to 25 AWHR systems for the four 1.7-inch OD hoses near each CC with easy access. The contractor shall also provide for hanging the 0.5-inch OD hand coiled hydraulic hose.

The contractor shall design and position the AWHR such that it is near the CC and located on the same side of the personnel pathway. The contractor shall integrate the AWHR and MIC designs using minimal floor space and to provide for easy operator and maintenance personnel access.

All control and indicator displays shall be located un-obstructed at eye level.

The four large 1.7” diameter hoses are to be auto-wound via auto traversing feed powered reels. If this power source is hydraulic, it must contain its own power system. The CC cannot be used to supply hydraulic power to the AWHR.

If the AWHR is mounted off the floor, the maximum operation height should enable a person with a height of 5’ 6” to run the AWHR standing with a normal reach flatfooted on the ground.

Hoses shall be capable or being auto-wound and un-wound under normal CC operating pressure.

Reels shall accommodate 70-foot minimum hose length.

Design of the AWHR shall use commercial off-the-shelf components as much as possible.

Hose reels shall be designed for manual un-winding by on person pulling the hoses out.

The auto-wind function shall have both manual and auto-shutoffs to reduce motor overloads and hose binding, and to stop retracting when the end of hose bumper is detected.

Additional requirements see Section 2.4, and 2.5 Common Requirements for AWHR and MIC (New or Converted PICU)

The contactor shall comply IAW with Section 7.1 thru 7.5

The contractor’s design to comply IAW with Section 7.6 -7.12

The contractor shall provide a warranty IAW Section 7.29

The contractor’s design shall incorporate safety features IAW Appendix C.

The contractor shall have obtained Government approval at Preliminary Design Review (PDR) prior to building the prototype MICs and prototype AWHR system. The contractor shall have obtained Government approval at the Critical Design Review (CDR) prior to building the remaining MICs and AWHRs.

The contractor shall build, install and test one prototype of each MIC (new or converted PICU) showing that it performs as well as the original PICU.

The contractor shall build, install and test one prototype of an AWHR showing that it performs as needed.

All prototype builds must be signed off as acceptable before remaining MIC and AWHAR builds and installations can continue.

Elevated platforms are acceptable as long as the design has been certified by a PE and located near the CC.

The contractor shall evaluate each CC location to understand the slightly different design integration challenges of each MIC and AWHR set. Different obstacles surrounding each CC may require such modifications as mounting methods, lengths of wiring / piping, connections, access points, platform design mods.

The MIC’s steady state discharge air temperature shall be regulated to within +/-4°F within 10 minutes of a cold start in all operating conditions.

The MIC ducting air outlet to be located and mounted at the same height from the floor as the CC air outlet.

The MIC ducting air outlet shall have a cover to protect against FOD when the aircraft hose is not attached.

The MIC cooling system shall be controlled with a two (2) position switch (i.e. OFF and ON).

Refrigerant….The MIC refrigeration system shall use R410A, R-404A, R-134a, or approved equivalent.

The MIC air conditioning unit shall be equipped with air filter(s) of the permanent, cleanable, reusable type and shall be readily removable.

A temperature and Air-Flow testing unit shall be designed with an orifice to provide an air discharge back pressure of 5.50 psig ± 0.25psig as indicated by the pressure gauge. Air discharge temperature shall be 34°F to 51°F and airflow rate may be 46.5 – 60 lb/min for design purposes. The orifice is used to perform maintenance checks on the air conditioning system without connecting to an aircraft.

A duct cover shall be incorporated as a means (e.g. closeable orifice) to keep out FOD when not being used for back pressure maintenance applications.

All materials used in the MIC and AWHR shall be fungus-resistant or will be suitably treated to resist fungus. Materials treated for fungus resistance shall retain their original electronic, physical, or other properties sufficiently to remain entirely suitable for the purpose, and shall not present toxic hazards for personnel or have corrosive effects on adjacent materials.

The period of effectivity of such treatment shall be at least equivalent to the service life of the part or component on which it is used.

Magnesium, magnesium alloys, zinc, and zinc alloys shall not be used in construction of the MIC and AWHR without specific approval of the procuring activity except where the material is used solely for sacrificial protection of adjacent materials against corrosion, the magnesium, zinc, or alloy part has no structural function, and the corrosion products will not interfere with function of adjacent parts or be deposited on adjacent surfaces susceptible to corrosion. Plating, dipping, or other means of surface treatment with such materials (including galvanizing) for corrosion resistance shall require approval.

Cadmium and cadmium compounds shall not be used in the construction of the MIC and AWHR.

The use of dissimilar metals in contact will be avoided as far as practical in the design of the MIC and AWHR. Where such conditions cannot be avoided, dissimilar metals in contact shall be protected in accordance with MIL-STD-889.

The use of materials that may emit products that are corrosive to adjacent materials will be avoided as far as practical. Where avoiding the use of such materials is not practical, the possible corrosive effects shall be controlled or eliminated by the provision of effective drainage and ventilation, choice of construction material, protective treatment (finishing) of corrosion- susceptible materials, or effective combinations of these measures.

When liquids or chemical solutions are used in the construction of equipment to clean or otherwise condition parts or surfaces, the manufacturer shall assure that such liquids are completely neutralized and removed and that the part is clean and dry before application of finish or completion of assembly.

Ventilation openings, when permitted by enclosure requirements, shall be designed to prevent accidental contact with live electrical circuits and mechanical moving parts.

During normal operation, the MIC and AWHR shall not produce a sound pressure level exceeding 75 A-weighted decibels (dbA) at a 10-foot radius from the center of the MIC and AWHR. Any sound absorbing or suppression material used in the construction of the MIC and AWHR shall be of the non-moisture absorbing type, so that condensation are not absorbed and held adjacent to metal structure and panels. Fiberglass, felt, and open cell foam shall not be used for sound suppression.

Drip troughs shall be provided to prevent water from draining on the operator, instrument panel, or into the enclosure. The bottom of enclosures shall be provided with necessary drains in order that fluids do not accumulate within the enclosure. Protection shall be provided for equipment lines and wiring within enclosures by routing the lines and wiring close to the structural members where they can be secured if necessary, and by providing protection or clearance where they can pass through panels and bulkheads.

Selection of instruments and controls (size, shape, function, operation, and location) will be such that they are appropriate for the intended function and performance requirements. Instruments and indicators (gauges and control measurement indicators) shall always be of the direct reading type (no calibration charts or curves requiring interpolation) and shall present to the viewer the required information in an easily understood manner. Normal and abnormal ranges shall be marked on the devices. All controls shall be marked, indexed, sized, and located such that control settings can be readily identified

U.S. customary weights and measures shall be the primary units of measurement for all physical dimensioning and measuring.

Selection of instruments will be governed by the accuracy and repeatability required in the measurement being made. They will also be of an appropriate type and style.

If analog mechanical pressure gauges are used for primary indications they shall be of the flush-mounted dial type with a minimum dial diameter of 2.5 inches and a measurement error not exceeding ±2% of full-scale reading at any measured reading, and shall conform to ASME B40.100. A calibration tap shall be included between each pressure gage supply line (reference gauges are excluded) and the isolation valve to facilitate the calibration of the pressure gage from the front of the control panel. If analog temperature gauges are used for primary indication they shall be of the flush-mounted dial type with a minimum dial diameter of 2.5 inches and a measurement error not exceeding ±2% of full-scale reading at any measured reading, and shall conform to ASME B40.200. For analog gauges, the normal operating value of the quantity to be indicated should be between 0.3 and 0.8 of full-scale deflection, wherever practicable.

Smooth and rapid operability of controls will be provided along with locking positions or detents if required by the controlled function. Controls and their related indicators shall be positioned on a noninterference basis when the control is being operated. These controls are usually on the front panel. Play and backlash in controls will be minimized. They shall operate freely and smoothly without binding, jerking, or other undesired actions. The controls will be single action, controlling only one parameter, and will not require further adjustment of other controls to obtain the correct setting. Control sizing, spacing, and shapes are to be determined by human factors criteria, considering the intended use and operating location of the equipment. Control orientation shall be such that to increase the controlled parameters the control will move either upward (to the top of the panel), clockwise, forward, or to the right. Controls shall have mechanized stops and locking devices, except for those designed for continuous rotation. The control shall have provisions to prevent the device from rotating in the panel. Knobs provided shall have a positive means of retention on their shafts. Plastic knobs shall use metal inserts and will not warp or crack. Switches, levers, and other controls will be of rugged design for long-term hand use.

Controls required for adjustment or calibration and not used for operation shall be mounted behind covered openings on the faces of the equipment from which they are most accessible when installed. If not hand adjustable, the adjustments should accept a common screwdriver blade. If only infrequent adjustment is required, access openings are not required, but the control shall be easily accessible when the item is opened for maintenance and will normally be adjustable with a common screwdriver. For mechanical devices, common hand tools should be used.

Instruments and control circuits shall have appropriate circuit protection, cable routing, and type of connector for their intended use.

The MIC and AWHR components, which must be periodically supplied with either a consumable product or uploaded/downloaded information, shall include provisions to accept the product and conduct it to the point(s) of use or storage within the equipment item. Such equipment items shall also contain provisions for draining (e.g., consumable products). Servicing provisions shall be accessible within 5 minutes, suitably identified, and shall be compatible with the servicing provisions equipment. Means shall be provided to prevent filling the expansion space of liquid tanks during servicing operations.

Functional Test: The Contractor shall operate the system at a no load condition continuously for no less than 12 hours. Proper operation of all controls, motors, adjusting mechanisms, and other accessories shall be verified during the test period. If the system fails under the no load testing, the deficiencies shall be corrected, and a new 12-hour test block shall be initiated. Functional testing shall continue until each of the PWS section 2.0 Requirements 2.1, 2.2.and 2.3 can operate properly, with no deficiencies, for 12 continuous hours. After the functional test is complete, the Contractor shall perform a full test on the aircraft. This test may be conducted in conjunction with operator training. The Contractor shall generate and deliver the Acceptance Test Plan 3 days after successful functional testing.

After the system has passed the functional and part run-off tests, the system will be accepted by the Subject Matter Expert (SME). The SME will sign the test report indicating that the test was witnessed by a representative of the using activity, and that the test was performed satisfactorily.

The Contractor shall provide operational and maintenance training as referenced in section 7.27 – 7.28

Maintainability Design Provisions of MIC and AWHR

The design shall facilitate maintenance and ensure that the maintenance portion of the availability requirement is met. The maintenance provisions will permit maintenance to be accomplished quickly, safely, accurately, and effectively with a minimum number of personnel, minimum skill level, no special tools, and minimum cost.

MIC and AWHR, if periodically supplied with a consumable product shall include provisions to accept the product and conduct it to the point(s) of use or storage within the equipment item. Such equipment items shall also contain provisions for draining (e.g., consumable products). Servicing provisions shall be accessible within 5 minutes, suitably identified, and shall be compatible with the servicing provisions equipment. Means shall be provided to prevent filling the expansion space of liquid tanks during servicing operations.

MIC and AWHR will be designed for accessibility. Components (e.g. controls, instruments, circuit breakers, fuses, batteries, power supplies, printed circuit boards, servicing provisions, and items requiring frequent maintenance) intended for Unit level, on equipment maintenance shall be accessible for removal and replacement without disassembling the mounting structure, removing undamaged parts, or removing panels that consume greater than 5 minutes of time to open. Components (e.g. fuses, circuit breakers, filters, etc.) shall be remotely located, if necessary, to provide the required accessibility. Covers or plates that must be opened or removed for daily or weekly access to components shall be equipped with panel latches. The MIC and AWHRs overall enclosure(s) shall be removable by overhead lift or manual lifting handles on each corner of the enclosure for improved maintenance action accessibility. Depending on the weight of the item, one or more individuals wearing a full complement of C/B or arctic (except mittens) protective equipment should be able to remove, replace, or repair malfunctioning components. Difficult-to-remove components shall not block access to components that are easier to remove. Line replaceable units (LRUs) shall be mounted so that they can be removed and replaced without removal of other LRUs or components.

Structural members of the MIC and AWHR shall not prevent access to or removal of LRUs. Replaceable items will not be mounted in a manner that will make them difficult to remove. Where accessibility depends upon removal of panels, cases, or covers, the design shall ensure that such items are not blocked by structural members or other items.

Large components, which are difficult to remove, shall be mounted so that they will not prevent convenient access to other items.

Items weighing over 80 pounds shall be mounted in such other manner that convenient access for the required handling equipment is provided.

Tools and Test Equipment: Check points, adjustment points, test points, test/servicing ports, cables, connectors, and labels shall be accessible and visible during maintenance. Sufficient space shall be provided for the use of test equipment and other required tools with gloved hand(s).

Rear Access: Sliding, rotating, or hinged equipment, to which rear access is required, shall be free to open or rotate their full distance and remain in the open position without being supported by hand. Rear access shall be provided to plug connectors except where precluded by any other operational requirements.

Components most critical to system operation and which require rapid maintenance shall be most accessible.

The MIC and AWHR design will include consideration of component removals for major disassembly and major repair of the equipment whenever practical. Only removal of the defective item should be necessary. Pilot guides, slides, and other similar features will be provided where they will appreciably facilitate removal and replacement. The design shall minimize improper installation by unsymmetrical configuration, different size connectors, guide pins, etc. Electrical enclosures required to be removed for maintenance or repair shall be designed with blind-mate connectors to facilitate removal and installation. Stainless steel guide pins shall be used in blind-mate connectors. The enclosure mounting shall be designed to retain mating of the connectors while meeting all requirements in this specification.

The MIC and AWHR design shall include provisions for attaching lifting devices, hard points for lifting devices, slots or protrusions for attaching extraction tools, etc., which are necessary during removal and replacement of components and subassemblies.

GOVERNMENT FURNISHED PORPERTY (GFP):

Cad & technical files:

See section 7.4

Limits of government furnished property:

Other than the equipment listed in Appendix G, no other government furnished property will be provided. The contractor shall provide all equipment and operators required to complete the work, including all lifts, and crane service.

Government furnished storage area:

Other than the minimal area around the CC site, see Appendix D, no other government area will be provided for staging or storing materials, parts or equipment.

DATA DELIVERABLES:

SAFETY PLAN (CDRL A001):

The contractor shall develop and implement a Safety Plan tailored specifically for this work which addresses the areas in Appendix B. Contracted personnel will be working with extremely heavy materials and varying heights. Therefore, the contractor shall specifically address the safety of contracted and Government personnel. Only one safety plan is required for the basic contract, but the safety plan shall be comprehensive to cover any work which may be ordered in any task order. The Safety Plan shall be submitted with the initial proposal to be reviewed with final acceptance by the OO-ALC Safety Office and the Program Manager.

QUALITY CONTROL PLAN (CDRL A002):

The contractor shall ensure quality service is maintained throughout the life of the contract, and shall prepare and implement (upon Government approval) a Quality Control Plan. Only one quality control plan is required for the basic contract, but the plan shall be comprehensive to cover any work which may be ordered in any task order. The plan shall reflect the Contractor’s overall approach, internal controls and establishment of procedures for controlling and accounting for tools along with a method to inventory their tools per Section 7.19, evaluating each of the major service areas (who, method, how often), for reporting to the Government, for resolving deficiencies, for identifying potential improvements, and for maintaining and making available to the Government, documentation reflecting quality control inspections and any corrective actions taken. The contractor shall respond with a mutually agreed upon mitigation plan for any discrepancy within seven calendar days. Any agreed upon mitigation plan shall not lead to a contract period extension unless modified by the CO.

ACTION ITEM TRACKING LOG (CDRL A003):

The contractor shall create and maintain an Action Item Tracking Log. Only one master log is required for the basic contract. Items identified during the implementation of each task order shall be added to the master log. The format shall be a Microsoft Excel spreadsheet or approved alternate. Alternate format must be an approved format for Government computer network systems. The log shall be a living document which is continually updated as needed. Action Items discussed at any and all project meetings shall be incorporated into the Action Item Tracking Log. Updated Action Item Tracking Log shall be emailed to the PM and the COR in electronic format at the conclusion of each meeting. Contractor shall provide hard copies of the Action Item Tracking Log upon request by the PM. Each item shall include:

· Task order number

· Item number

· Item description

· Date item was raised

· Owner assigned to complete item (to be an individual, not an organization)

· Target complete date

· Actual complete date

· Resolution and comments section

AS-BUILT DATA PACKAGE (CDRL A004):

The contractor shall provide a draft copy of the As-Built Data Package within 30 days of completing:

· Requirement #1 of this contract

· Requirement #2 of this contract

· Requirement #3 of this contact The data package shall be IAW the following:

The package is to be comprehensive and include all information required to properly document the final designs developed and systems implemented in the performance of this contract. The package shall include, but is not limited to, all drawings, part lists, specifications, PE calculations, and written instructions necessary for an independent contractor to construct, install and/or repair all designs included in this contract. The package shall include documentation of all final system settings and configurations. The package shall be divided into the following three sub-packages; drawings, specifications and PE calculations.

All drawings shall be compiled into a single drawing sub-package with an appropriate index sheet which identifies the location of each drawing. All drawings in the package shall be formatted to the same paper size. All drawings shall be to a known scale and dimensionally accurate.

The drawing sub-package shall include the final version of all drawings created in the fulfillment of this contract. Drawings included shall be, but are not limited to, all shop drawings, part drawings, detail drawings, assembly drawings, layout drawings, installation control drawings, construction drawings, elevation and section drawings, etc..

Drawings must have a 309 AMXG/EN approved Title Block with the AF logo being the most dominant. Drawings shall be formatted to be legible when printed on a max paper size of ANSI “D” (22” x 34”). Any drawings submitted which are formatted for paper larger than ANSI “B” (11” x17”), shall include a copy printed half size (i.e. “D” size drawings shall include a copy printed half size on “B” size paper, “C” size drawings shall include a copy printed half size on “A” size paper.)

The drawing sub-package shall be provided in two electronic formats and in a printed and bound hard copy. Contractor shall provide up to 5 printed hard copies at PM’s request at no additional cost to the government. The electronic formats shall be in both Adobe PDF and CAD formats. The CAD format shall be either AutoCAD 2015 or SolidWorks 2015. The PE’s seal shall be included in both the printed and PDF formats, but not in the CAD format.

All specifications shall be compiled into a single specifications sub-package and include appropriate indexes. The specification sub-package shall be submitted in two electronic formats and in a printed and bound hard copy. Contractor shall provide up to 5 printed hard copies at PM’s request at no additional cost to the government. The electronic formats shall be in both Adobe PDF and an editable Microsoft Word format.

All PE calculations shall be compiled into a single PE calculations sub-package. Each PE’s calculations shall include the PE’s seal and shall be submitted in Adobe PDF format only.

All electronic files shall be compatible with a Microsoft Windows OS.

Contractor shall provide draft copies of each data package for government review and acceptance prior to providing final copies. Draft copies shall be provided in both a digital format and in a printed and bound hard copy.

ICR MEETING MINUTES (CDRL A005):

Meeting minutes shall be taken digitally during the Implementation, Coordination and Review (ICR) meetings, agreed on by all present at the meeting, and emailed to the PM and COR in electronic format at the conclusion of the meeting.

TCIR/DART RATES (CDRL A006):

The Contractor shall provide from its OSHA 300 information the Total Case Incident Rate / Days Away Restricted or Transferred (TCIR/DART) rates by 15 January of each year to the CO for submission as part of the installation’s annual OSHA Voluntary Protection Program (VPP) self-evaluation report.

MISHAP NOTIFICATION (CDRL A007):

A written or email copy of the mishap notification shall be sent within three calendar days to the COR, who will forward it to OO-ALC Safety. For information not available at the time of initial notification, the contractor shall provide the remaining information no later than 20 calendar days after the mishap, unless extended by the ACO.

CONTRACTOR ROSTER (CDRL A008):

The Contractor shall include an updated Contractor Roster which identifies, for all employees working on base supporting this contract for more than 5 continuous days, the company name, employees’ names, Government POC names, employees’ supervisor’s (or lead’s) names, DBIDS (if issued) and line badges (if issued) no later than 15 days prior to on site work. Changes made to the list or status of employees shall be provided one week prior to the scheduled work. This will ensure the Government is aware of all contract employees on site.

SCHEDULE

IMPLEMENTATION PHASE

1) One prototype PICU converted to a MIC per para. 2.2 and one prototype AWHR per PWS para. 2.3 to be delivered three months ARO.

2) One prototype new MIC per PWS para. 2.1 and one prototype AWHR per PWS para. 2.3 to be delivered three months ARO.

3) 6 Sets of MIC and AWHR units installed in Building 225 East Side (Appendix D)

4) 6 Sets of MIC and AWHR units installed in Building 233 North Side (Appendix E)

5) The following schedule implementations shall be scheduled at a mutually convenient time for both parties:

a. 8 MIC and AWHR units installed in Building 225 TBD (to be decided)

b. 5 MIC and AWHR units installed TBD

MIC and AWHR implementation time period: All services and installations for each control console shall be completed within a 1 week max time frame from start to finish while aircrafts on either side are being overhauled.

All work required near each control console, such as on associated infrastructure, modifications to existing systems, and installation of new systems, shall be completed prior to turn over to aircraft production and within the allotted time period for each installation. Actual schedule will be defined at task order level.

IMPLEMENTATION PHASE START DATES:

Dates for working in each MIC and AWHR will be provided by 309 AMXG/EN as the schedule matures. At the Governments sole discretion, and at no additional cost to the government, the start dates may be as close as 3 weeks apart. Government may adjust schedule as required up to 30 days prior to the start date of each phase. Contractor shall attend ICR meetings and adjust schedule as coordinated in those meetings. Start dates will be defined at task order level and reviewed/adjusted at ICRs as needed.

WORK SCHEDULE COORDINATION:

Work hours when on site at HAFB to be IAW with Section 7.14

Contractor shall coordinate all on-site work and schedules with the PM and schedule all on-site work around aircraft production activities. The PM will provide initial control console availability schedules to the contractor, but may alter established schedules as needed and at no cost to the Government unless it is within 30 calendar days of an established Control console availability date. The contractor shall adapt their schedule to match Control console availability schedules as they are revised.

The area between each aircraft will be cleared for access during each install. No Dock will be shut down for any part of the installation. (Note: Aircraft Assembly Stands will not be cleared out.)

During installation the area around each CC shall be roped off to separate the construction site from the production area.

There will be minimal area for storage near each CC so materials and components need to be brought in as needed and staged off site until installed.

All major fabrication to be completed off site prior to installation to minimize schedule time frame.

After acceptance of section 2.4.5, multiple MIC and AWHR units should be ready for installation at any given time to help with scheduling options.

COORDINATION WITH PRODUCTION: Contractor shall coordinate all on-site work and schedules with the PM and schedule all on-site work around aircraft production activities. The PM will provide initial dock availability schedules to the contractor, but may alter established schedules as needed and at no cost to the Government unless it is within 30 calendar days of an established dock availability date. The contractor shall adapt their schedule to match dock availability schedules as they are revised.

FORMAL ICR MEETINGS & REPORTS: Contractor shall attend ICR (Implementation, Coordination, and Review) meetings. Meetings shall be held weekly until the work is substantially completed. Meetings are to be held in a 309 AMXG provided conference room. At each meeting contractor shall perform the following:

Keep meeting minutes/attendance lists. Meeting minutes shall be taken digitally during the meetings, agreed on by all present at the meeting, and emailed to the PM and to the COR in electronic format at the conclusion of the meeting (CDRL A005).

Update the Action Item Tracking Log IAW section 5.3. The updates shall be completed during the meeting and agreed upon by all present.

SAFETY & PROJECT CONTROL REQUIREMENTS:

Tool, Material and Equipment Control:

Contractors performing functions in industrial areas within OO-ALC shall have a method for controlling and accounting for tools used. The Contractor’s tool control program shall be outlined in the Quality Control Plan and shall be coordinated with respective contracting officer and contract functional manager or his/her designated reprehensive. All contractors working within OO-ALC shall be required to inventory their tools at the beginning of the shift, at the end of each task, and at the end of each shift to check for any lost or missing tools. Any lost tools not found shall be reported immediately to the CO, the production area supervisor, and the 309 AMXG tool manager.

SAFETY:

While performing work under this contract, the Contractor shall follow Appendix C and section 7.21 to provide the Government a Safety Plan with their proposal.

The Air Force is part of the OSHA Voluntary Protection Program (VPP). The Contractor is required to attain familiarization with the requirements of VPP. Information on the VPP can be accessed at http://www.osha.gov/dcsp/vpp/index.html. VPP requirements apply to contractors whose combined total of work hours for both employees and sub-contractors is more than 1,000 hours per quarter on base. The Contractor shall provide from its OSHA 300 information the Total Case Incident Rate/Days Away Restricted or Transferred (TCIR/DART) rates by 15 January of each year to the CO for submission as part of the installation’s annual OSHA Voluntary Protection Program (VPP) self-evaluation report (CDRL A006).

The contractor shall ensure their employees are made aware that the performance of these services will occur in industrial areas. The C-130 aircraft workload adjoining the job sites has the potential to expose workers to hazardous materials which may include, but is not limited to, lead, methylene chloride, hexavalent chrome and cadmium. While the contractor will not perform duties in a marked and signed regulated area (where exposures are expected to exceed the permissible exposure limits set by 29 CFR 1910), there may be contact hazards with these materials during cleanup. The contractor shall ensure proper protective measures and training are taken to protect contracted employees from these hazards. The 75th Air Base Wing (ABW) Bioenvironmental Engineering Flight has produced industrial hygiene assessments of these areas and are for informational purposes only. The contractor will be responsible for conducting a Hazard Assessment in accordance with 29 CFR1910.132(d)(2).

GENERAL REQUIREMENTS

GOVERNMENT CONTRACT MANAGEMENT:

Contracting Officer (CO). The CO is a government official designated to enter into and administer contracts. The CO has the sole authority to issue modifications to the contract, resolve disputes, and to terminate the contract. No conversation, direction or recommendation, given or implied by government personnel, that will affect the scope, schedule, or price of this contract, shall be acted upon by the contractor unless first approved by the CO. Under no circumstances shall “approval” by the CO be interpreted as a release of the contractor from responsibility to fulfill requirements of the contract.

Air Force Project Manager (PM). The PM is a government employee designated by the CO. The PM shall act as the technical advisor for the government. Only the PM (or designated alternate) has authority to review and accept contract deliverables. The PM will have the right to reject or require correction of any deficiencies found in products or deliverables. The PM may provide technical interpretation and/or direction to ensure the project is in compliance with the contract technical requirements, but the PM does not have authority to alter the requirements of this contract. If the contractor believes directions received from the PM are outside the scope or confines of the contract, the contractor shall notify the PM and CO prior to proceeding.

VERIFICATION & INSPECTION OF EXISTING CONDITIONS:

It is the contractor’s responsibility to inspect and verify existing measurements, site conditions, available utilities, etc. prior to bid.

ELECTRONIC AND PAPER DOCUMENTS:

Unless otherwise indicated, all written correspondence and submitted documents shall be in electronic format compatible with a Microsoft Windows OS. Acceptable formats are Adobe PDF, Microsoft Word, Microsoft Excel, Microsoft Power Point, JPG, SolidWorks and AutoCad. Other formats must be approved by the PM prior to delivery. Unless otherwise noted, all deliverables (CDRL’s) shall be in Adobe PDF format. Contractor shall provide up to three (3) printed copies of electronic documents upon request.

GOVERNMENT SUPPLIED CAD & TECHNICAL FILES:

Upon written request, and subject to PM review of project relevancy, contractor security approval and document availability, the government shall supply paper and/or electronic copies of all government owned technical documents required for the completion of this project including, but not limited to:

● CAD files of design packages generated specifically for this contract

● Reference CAD and/or PDF files of relevant existing equipment

● Reference CAD and/or PDF files of relevant facility as-built drawings

The contractor shall not copy or distribute government supplied documents without prior written consent. At the conclusion of the contract the contractor shall return all technical documents supplied by the government and shall not keep copies of any government supplied documents or copies of designs developed in the fulfillment of this contract, without first receiving written permission from the government. The contractor shall ensure all sub-contractors and suppliers are in compliance with this requirement.

OWNERSHIP OF PROJECT DESIGNS & DOCUMENTATION:

Unless noted otherwise, all designs, documents and intellectual property developed in the performance of this contract shall be solely owned by the US government and shall be free of any encumbrances. The contractor does not have any right or claim to any portion of it and shall not use, sell, or distribute it in any fashion other than in fulfillment of this contract. The contractor may not use this intellectual property, in part or in whole, for any commercial gain outside the fulfillment of this contract. At the conclusion of the contract the contractor shall return all original and new intellectual property related to this contract and shall not keep copies in part or in whole. This requirement applies to both digital and hard copies. The contractor shall ensure all sub-contractors and suppliers are aware of and in compliance with this requirement.

GOVERNING REGULATIONS & GENERAL DESIGN REQUIREMENTS:

Contractor shall design and/or implement the unit(s) and/or system(s) to safely perform the intended operations. General and specific design and/or implementation requirements in this contract are minimum requirements. Contractor shall identify and incorporate industry best standards and specifications into the appropriate design and/or implementation elements of this contract. Any elements required for complete and fully functioning systems shall be included. Contractor shall ensure all designs and/or work implemented in the performance of this contract are in accordance with AF, local, city, state and federal laws, rules, regulations, codes, and standards. All designs and/or implementations shall meet or exceed applicable OSHA, AFI and ANSI standards. In particular the contractor shall ensure the designs and/or implementations meet requirements found in the latest edition of AFI 91-203. All installations shall comply with local and national codes for mechanical work, fire protection, safety, health, environmental protection, and other cognizant authority germane to the specific work order. Contractor shall ensure fabrications are in accordance with the latest edition of the AISC Steel Construction Manual at time of award. Unless noted otherwise, all steel components shall be fabricated from structural steel shapes conforming to ASTM A500, A513, and A36 materials or better. Unless noted otherwise, all bolted connections shall use A325 structural bolts, SAE Grade 5, or SAE Grade 8 commercial hardware or better. Contractor shall identify all system components on shop drawings with assembly numbers which are also permanently stamped, tagged, or engraved, on each component. All components shall be equipped with safety devices such as covers, guards, and interlocks for protection from mechanical, electrical, and operational hazards. In case of conflict the most stringent requirements are applicable.

DESIGN FOR FOREIGN OBJECT DEBRIS (FOD) CONTROL:

Except for removable railing sections or other large removable components, any smaller item incorporated into a design and/or implementation which can be removed without a tool (i.e. lock pins, quick release band clamps, etc.) shall be permanently attached to the unit with the use of a lanyard (or other AMXG/EN approved device) to prevent the item from becoming FOD (Foreign Object Debris) and causing damage to an aircraft.

RAILING RETENTION:

All removable guardrails/railings, incorporated into the design and/or implementation of this contract, shall have a retention device which prevents unintentional removal of handrail section. Retention device shall be a ball lock pin such as McMaster-Carr #93750A803 or PM approved alternate. All removable pins shall have a lanyard or other PM approved device to secure the removable pin.

NON-SLIP SURFACES:

All stair treads and walking surfaces, incorporated into the design and/or implementation of this contract, shall have a slip resistant surface made from diamond tread plate with non-slip paint, serrated expanded metal, traction tread, or other PM approved surface.

OPERATION, SAFETY & WARNING SIGNS:

Equipment and component installations shall include all operation, warning and safety signs as required to instruct users in the safe operation of the equipment. Signage shall include, but are not limited to, warnings and instructions required for maximum capacity, lock pins, safety cautions, towing restrictions, usage instructions, Etc. All signage shall be approved by PM prior to fabrication and installation.

PAINT:

Unless otherwise noted, all surfaces without factory applied paints or industrial grade corrosion resistant coatings shall be painted per the following or PM approved equivalent.

All surfaces shall be free of corrosion, rust, oil, grease, and dirt and shall be cleaned and thoroughly dried before paint and primer applications. All surfaces shall be prepped, and painted per paint manufacturer’s recommendations.

Except for final touch-up, all surfaces shall be shop primed and painted using an airless sprayer. All coats shall be even in thickness and coverage and free of drips and runs. Do not paint over factory labels or signage.

All steel (except galvanized steel) and other surfaces, unless otherwise noted, shall have at least one coat of primer per paint manufacturer’s recommendations.

Unless otherwise noted, all surfaces shall be painted with a minimum of 2 coats of industrial grade epoxy coatings per paint manufacturer’s recommendations or shall be powder coated per coating manufacturers recommendations. Contractor shall submit paint manufacturer data and recommended application sheets to PM for approval.

Unless noted otherwise, the following color scheme shall be applied. All modifications to existing systems, structures, equipment, etc. shall be painted to match existing. For new fabrications, all surfaces which are adjustable shall be safety yellow. Items which shall be painted safety yellow include, but are not limited to; removable railing sections, adjustable deck surfaces, other movable safety devices, etc. All steps or abrupt change in elevation of deck surfaces shall receive a safety yellow stripe on the edge of each step. The stripe shall be a minimum of 2” wide. All fire and safety and electrical equipment/areas shall be red. Contractor shall obtain color selection from the PM for all other surfaces.

Contractor shall verify colors of all surfaces with the PM prior to painting. Contractor/supplier shall provide a color chart to the PM for final color selection.

GENERAL QUALITY:

Unless noted otherwise all materials shall be new and free of corrosion or other defects. All components and implementations shall be manufactured and installed in accordance with industry best standards of quality and workmanship. All surfaces shall have factory or shop applied paints or coatings wherever possible. Field touch-up of painted and/or coated areas shall be kept to a minimum. Field touch-up all components and installations as required to provide a factory finished / shop finished professional look. Field work shall be finished to match factory/shop standards. No “chop” or “hack” jobs shall be accepted. Contractor shall ensure all installations are plumb, level, and flush with adjacent surfaces. All burs, weld splatters, sharp corners, and sharp edges shall be removed and ground smooth prior to painting. Final components, installations, and installation areas shall be completely cleaned and free of installation debris, road grime, etc. Contractor shall clean surfaces thoroughly prior to installation, prepare surfaces using the methods recommended by the manufacturer, and install in accordance with manufacturer’s instructions.